Photovoltaic module mounting system

ABSTRACT

A photovoltaic (“PV”) module mounting system that includes a base having a platform with a plurality of supports extending upwardly therefrom. The PV module mounting system is secured to a support structure, such as a roof, and a mounting apparatus is adapted to fixedly secure a PV module to the base. A plurality of PV module mounting systems can be configured for the installation of an array of PV modules.

This application claims priority from provisional application Ser. No. 61/544,933, filed on Oct. 7, 2011, which is incorporated herein in its entirety.

FIELD OF INVENTION

The present invention relates to a mounting system having a base for supporting and securing a photovoltaic module on a support structure.

BACKGROUND OF THE INVENTION

Photovoltaic (“PV”) modules, also known as solar panel modules, typically include a photovoltaic panel and the associated electrical wiring for connecting the module to a desired circuit. PV modules are typically mounted to the roofs of buildings or homes in order to place them in the best position for receiving the necessary sunlight to generate electricity. However, mounting the modules on such structures can be difficult since they need to be properly aligned in order to work most efficiently and also to be more aesthetically pleasing.

Working on the roofs of structures can be difficult in that equipment must be safely hauled up to the roof. When working on pitched roofs, it is especially difficult since the materials must be properly secured, even prior to installation, in order to prevent them from falling off. Photovoltaic modules are relatively heavy devices and are also fragile. Therefore, they are subject to breakage if not handled properly.

PV modules are typically mounted on a base which may consist of a plurality of spaced elongate rails. The rails are designed to accommodate a plurality of PV panels along their length. Such rails must be properly aligned and spaced from each other in order to provide a mounting surface which will engage the PV module. If one rail is not parallel to the other and spaced appropriately from the other to provide the correct amount of support for the module installation, problems will occur. Also, rails may have to be adjusted in length to accommodate a particular installation. Therefore, a significant amount of time and effort must be expended on top of a roof to install and align the rails.

Accordingly, it is desirable to provide a mounting base for a PV module which can be easily installed and aligned on a roof and allows for the PV module to be easily and quickly installed thereon.

SUMMARY

The present invention is a photovoltaic (“PV”) module mounting system that includes a base and a plurality of mounting apparatus. The base includes a platform having a plurality of supports, wherein each support extends upwardly from the platform to a distal end. The plurality of mounting apparatus is adapted to fixedly secure a photovoltaic module to the plurality of supports. The PV module mounting system can also include a second base formed similarly to the first base. The first and second bases include complementary interlocking structures for aligning the first base with respect to the second base.

The platform can include a rectangular frame having first and second ends and first and second sides. The complementary interlocking structures are preferably located on the first and second sides and the first and second ends of the rectangular frame. The rectangular frame can also have two pairs of diagonally opposed corners and first and second diagonal members extending therebetween. The rectangular frame can also include four elongate members connected at four corners. The four elongate members can have a plurality of openings therethrough, which are adapted to receive fastening devices to secure the base to a support structure.

The platform can have first and second pairs of supports located at the first and second ends of the frame, respectively. The first and second pairs of supports can have first and second heights, respectively. The heights are equal to the distance from the platform to the distal end of the support. Preferably, the height of the first pair of supports is greater than the height of the second pair of supports so that the PV module supported by the supports is installed on the base at an angle and has a slope or a pitch downwardly between the first and second pairs of supports. This is especially desirable when the PV mounting base is installed on a substantially flat support structure.

Each of the supports has an aperture in the distal end for attaching a PV module. The locations of the apertures correspond to the locations of mounting apertures in the PV module. This allows fastening hardware, such as a bolt, to pass through the mounting aperture in the PV module and into the aperture in the support. In a preferred embodiment, the aperture is tapped (i.e., threaded) or includes a captured nut so that the bolt can be threaded into the distal end of the support. The plurality of supports can be adjustably positioned at a plurality of locations on the platform. This allows the supports to be repositioned so that the apertures in the supports align with the mounting apertures in PV modules with different mounting aperture configurations.

The present invention is also a PV module mounting system that includes a plurality of PV modules and a plurality of mounting bases. Each mounting base supports one PV module and is constructed as described above. The interlocking structures on the sides and ends of the base cooperate to align adjacent bases with each other. The mounting bases can be joined to form an array that can be configured to conform with the dimensions of the support structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a preferred embodiment of the PV module mounting base showing a PV module prior to installation thereon;

FIG. 2 is a side perspective view showing the PV module mounted on the base shown in FIG. 1;

FIG. 3 is a bottom perspective view showing the PV module mounted on the base shown in FIG. 2;

FIG. 4 is a perspective view of an array of mounting bases secured to the roof of a building.

FIG. 5 is a detail perspective view of the mounting base with a sectional view of a preferred embodiment of the support structure;

FIG. 5A is a detail side view of the mounting base shown in in FIG. 5;

FIG. 6 is a perspective view showing a PV module and a mounting base secured to a support structure using ballast;

FIG. 7 is a top perspective view showing an alternative embodiment of the present invention for securing a PV module in a pitched orientation;

FIG. 8 is a perspective view of a pair of mounting bases with the PV modules in shown in phantom; and

FIG. 9 is a side elevational view of the base shown in FIG. 8 with a PV module installed on the base.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is a photovoltaic (“PV”) module mounting system having a base with a plurality of upwardly extending supports for supporting a PV module. The PV module mounting system provides an individual base for each PV module. The base includes a platform having a plurality of supports, which can be adjustably positioned on the base and which can have different heights. As used herein, the height of the supports is the distance from the top surface of the base, on which the support is secured, to the distal end of the support. The distal end of each support can have an aperture (preferably threaded) for receiving a mounting apparatus, such as a bolt, which is adapted to fixedly secure a PV module to the base.

The PV module mounting system can be formed into an array that includes a plurality of PV modules and a plurality of individual mounting bases. Each mounting base supports one of the PV modules and includes a plurality of supports extending upwardly therefrom. The supports extend from the base to a distal end and are adapted to support the PV module at a plurality of locations. The bases are secured to a support structure and the supports offset the PV module a predetermined distance from the support structure. Typically, four supports are used to install a PV module on a base. The supports can have different heights depending on the pitch of the support structure (e.g., a roof) so that the PV modules can be oriented at different angles to maximize the exposure to sunlight.

With reference to FIGS. 1-3, a photovoltaic module mounting system 10 is shown. The mounting system 10 includes a base 12, which secures a PV module 14 to a support structure 16, such as the roof of a building or house. The mounting base 10 includes a platform 18 having a plurality of upwardly extending module supports 20. The supports 20 are spaced apart to support the PV module 14 at various locations. The platform 18 may be formed in a number of configurations. For example, as shown in FIG. 1, the platform 18 is formed by four elongate members 22 that are joined together at four corners 24. The elongate members 22 form a frame-like structure having an open center 26. The elongate members 22 are generally flat members having a height less than their width or length. In an alterative embodiment shown in FIG. 7, the platform 28 includes a number of elongate inner 30 and outer 32 members. In a further alternative embodiment (not shown), the platform can be a planar generally continuous member having a substantially closed central region.

In the PV module mounting system 10, each PV module 14 is individually supported by a designated base 12. In a preferred embodiment, the base 12 has a configuration generally similar to the PV module 14. For example, if the PV module 14 is rectangular, the base 12 is generally rectangular.

The base 12 may be formed of a molded plastic material with the module supports 20 integrally formed with the elongate members 22. Alternatively, the elongate members 22 of the platform 18 can be formed as one piece and each of the module supports 20 may be fixedly secured to the platform 18 using screws, bolts, clips or other fastening devices in a manner well known in the art. It is within the contemplation of the present invention that the base 12 may be formed of other materials including wood, composites, or metal.

In the embodiment show in FIGS. 1-6, the module supports 20 are located at the four corners 24 of the platform 18. The supports 20 are secured in place and extend upwardly from the elongate members 22 to a substantially flat mounting surface 34. In one embodiment, the module supports 20 have generally the same height. The supports 20 can be formed in a variety of shapes such as a frusto-pyramidal shape, as shown in FIG. 1, wherein they taper inwardly as they extend towards the distal end. The mounting surface 34 of the plurality of supports 20 contacts the underside 36 of the PV module 14. Alternatively, the module supports 20 may be tubular shaped or a rectangular block, or any other of a number of configurations having a generally flat mounting surface on the distal end for supporting the PV module 14 thereon.

With specific reference to FIG. 1, the module supports 20 are arranged on the base 12 such that a first set of two supports 38 are aligned with each other in the X direction at one end. A second set of two supports 40 are also aligned with each other in the X direction on the opposite end. The first set of supports 38 and the second set of supports 40 are offset from each other in the Y direction. This spacing allows the base 12 to support the PV module 14 at four locations so that the weight of the PV model 14 is evenly distributed.

With reference to FIGS. 1, 5 and 5A, the module supports 20 may include an opening 42 at the distal end for receiving module mounting apparatus such as fasteners 44, which may be used to secure the PV module 14 to the base 12. In one embodiment, the PV module 14 includes apertures 46 through which the mounting fasteners 44 may extend. The mounting fasteners 44 can be bolts and the supports 20 may include captured nuts 48 secured therein. As used herein, the term “captured nut” refers to a nut that is permanently attached to the support. For example, when a support is made from plastic, the nut is installed in the support during the extruding or molding process. Securing the PV module 14 to the base 12 is accomplished by placing the PV module 14 on top of the base 12 with the apertures 46 in the PV module 14 aligned with the apertures 42 in the supports. Fasteners 44 are then inserted through the apertures 46 in the PV module 14 into the supports 20. FIG. 1 shows a frameless-type PV module 14. For PV modules 14 having frames (not shown), the frame may have openings 50 therein that accept fastening hardware to secure the PV module 14.

In order to secure the base 12 to the support surface 16, the elongate members 22 of the platform 18 may include a plurality of openings 50 extending therethrough, which accept fastening hardware 52. The fastening hardware 52 is used to fixedly secure the base 12 to the support structure 16, such as the roof of a building or house. The fastening hardware 52 may include threaded bolts of a type know in the art, which preferably form a waterproof seal between the bolt and the support structure in order to prevent water from leaking in through fastening hardware attachment points. Alternatively, a suitable sealant material can be placed about the fastener 44 and base 12 to affect a watertight seal with the support structure.

With reference to FIG. 6, in addition to, or instead of, using fastening hardware, the base 12 may be secured to the support structure 16 using mounting ballast 54. Such ballast can be cement blocks, sandbags or other relatively heavy items. This installation may be most beneficial in a flat roof installation where there is less likelihood of the base 12 sliding with respect to the support surface. By not using fasteners extending into the flat roof, the water-resistant integrity of the flat roof is not compromised.

A plurality of PV module bases 12 can be secured to a support structure in an array 56 as shown in FIG. 4. An installer arranges the bases 12 in a desired configuration. Since the bases are lightweight and compact, it is easy for the installer to place the bases in any desired configuration. Once the bases are firmly secured to the support structure, the PV modules 14 may be brought to the roof and secured to the bases 12. Once the bases 12 are secured to the support structure, all the installer needs to do is place the PV module 14 over the base 12 and align the apertures 46 in the PV module 14 with the support apertures 42. The PV module 14 may then be secured to the base 12 using the mounting fasteners 44. There is no need for any further alignment of the PV modules 14. Accordingly, once the bases 12 are installed, each of the PV modules 14 secured to the bases 12 will be properly aligned.

An alternative embodiment of the mounting base 70 is shown in FIGS. 7 to 9. The base 70 includes a platform 28 supporting a plurality of spaced module supports 74. The dimensions of the perimeter of the base 70 are preferably the same as or slightly larger than the dimensions for the perimeter of the PV module 14. This permits the side edges of adjacent mounting bases 70 to be butted together when mounted to a structure.

When mounting PV modules 14 to structures, especially on flat roofs, it may be desirable to pitch the PV modules 14 with respect to the roof. Accordingly, the height of the module supports 74 may be varied in order to provide the desired pitch of the PV module 14. To achieve this, a first set of supports 76 may be greater in height than a second set of supports 78. Pitching the PV modules 14 at an angle to the roof allows the PV modules 14 to be advantageously oriented to receive sunlight. In addition, rain and snow will tend to run off the top surface of the PV module 14. Pitched PV modules 14 also tend to stay cleaner as water draining from the top surface carries away dust and dirt that may settle on the PV module 14.

The base 70 may be formed as a one piece unit with the supports 74 formed at different heights. Alternatively, the supports 74 may be removably securable to the base 70 such that an installer may select supports 74 of different heights and secure them to the base 70 in order to customize the pitch of the PV modules 14 for a particular installation. The base 70 can also have a plurality of mounting locations for the supports 74 so that they can be positioned to accommodate PV modules 74 with different mounting aperture configurations.

In the embodiment shown in FIGS. 7 to 9, the base 70 has crossing members 80 extending diagonally from one corner to the other and crossing at the middle. An installer may place fastening hardware through these members 80 to attach the base 70 to a roof. If the base is formed of a plastic material, the fasting hardware such as lag bolts may be driven right through the material in the roof. Alternatively, an installer could drill a pilot hole, or the holes could be preformed in the base.

The mounting bases 70 may further include interlocking structures 90 which align one or more bases 70 with respect to each other. In one embodiment, the interlocking structures 90 are alternating protrusions 92 and depressions 94 formed in the edges on the sides and ends of the bases 70. The left and right side edges 96 and 98 of the base, as well as the opposing ends 100, 102, may have the location of the protrusion and depression inverted. Thus, the right side edge of one base can be interlocked with the left side edge of the other base. Similarly, the edges on the ends 100 and 102 may have the location of the protrusion and depression inverted. In this way, the bottom side edge of one base may be interlocked with the top edge of another adjacent base. This interlocking features aids in installation by aligning the adjacent bases with each other. Therefore, once an installer fixes the position of one base 70 on the roof, the position of the remainder of the bases 70 in the array is easily determined.

In addition, by inverting the arrangement of depressions and protrusions in the opposing sides and ends, all of the interlocking bases are the same. Therefore, only one type of mounting base needs to be used by an installer. For example, if an installer wants to install 10 PV modules, then 10 of the same type of bases can be used. This greatly simplifies installation and part management logistics.

Thus, while there has been disclosed what is presently believed to be preferred embodiments of the invention, those skilled in the art will appreciate that other and further changes and modifications can be made without departing from the scope or sprit of the invention, and it is intended that all such other changes and modifications are included in and are within the scope of the invention as described in the appended claims. 

What is claimed is:
 1. A photovoltaic (“PV”) module mounting system comprising: a first base including a platform having a plurality of supports, each support extending upwardly from the platform to a distal end; and a plurality of mounting apparatus adapted to fixedly secure a PV module to the plurality of supports.
 2. The PV module mounting system as defined in claim 1, further comprising a second base formed similarly to the first base, the first and second bases including complementary interlocking structures for aligning the first base with respect to the second base.
 3. The PV module mounting system as defined in claim 1, wherein the platform comprises a rectangular frame having first and second ends and first and second sides.
 4. The PV module mounting system as defined in claim 3, wherein the rectangular frame has two pairs of diagonally opposed corners and first and second diagonal members extending therebetween.
 5. The PV module mounting system as defined in claim 3, wherein the rectangular frame comprises four elongate members connected at four corners.
 6. The PV module mounting system as defined in claim 5, wherein the four elongate members have a plurality of openings therethrough, which are adapted to receive fastening devices to secure the base to a support structure.
 7. The PV module mounting system as defined in claim 3, wherein the platform has first and second pairs of supports located at the first and second ends of the frame, respectively.
 8. The PV module mounting system as defined in claim 7, wherein the first and second pairs of supports have first and second heights, respectively, wherein each height is equal to the distance from the platform to the distal end of the support, and wherein the height of the first pair of supports is greater than the height of the second pair of supports.
 9. The PV module mounting system as defined in claim 3, wherein the complementary interlocking structures are located on the first and second sides and the first and second ends of the rectangular frame.
 10. The PV module mounting system as defined in claim 1, wherein each of the supports has an aperture in the distal end, and wherein the locations of the apertures corresponds to the locations of mounting apertures in the PV module.
 11. The PV module mounting system as defined in claim 1, wherein the plurality of supports can be adjustably positioned at a plurality of locations on the platform.
 12. A PV module mounting system comprising: a plurality of PV modules; and a plurality of mounting bases, each mounting base supporting one of the plurality of PV modules, each of the mounting bases comprising a plurality of supports extending upwardly from the base to a distal end and adapted to support the PV module, each of the bases being adapted to be secured to a support structure, and the plurality of supports spacing the PV module from the support structure.
 13. The PV module mounting system as defined in claim 12, wherein each of the plurality of bases includes complementary interlocking structures that cooperate to align adjacent bases with each other.
 14. The PV module mounting system as defined in claim 13, wherein each of the mounting bases is similarly formed.
 15. The PV module mounting system as defined in claim 13, wherein each mounting base further comprises a rectangular frame having first and second ends and first and second sides, and wherein the complementary interlocking structures are located on the first and second ends and the first and second sides of the rectangular frame.
 16. The PV module mounting system as defined in claim 15, wherein the rectangular frame has two pairs of diagonally opposed corners and first and second diagonal members extending therebetween.
 17. The PV module mounting system as defined in claim 15, wherein the rectangular frame comprises four elongate members connected at four corners.
 18. The PV module mounting system as defined in claim 17, wherein the four elongate members have a plurality of openings, which are adapted to receive fastening devices to secure the base to the support structure.
 19. The PV module mounting system as defined in claim 15, wherein each base has first and second pairs of supports located at the first and second ends of the frame, respectively.
 20. The PV module mounting system as defined in claim 19, wherein the first and second pairs of supports have first and second heights, respectively, wherein each height is equal to the distance from the base to the distal end, and wherein the height of the first pair of supports is greater than the height of the second pair of supports.
 21. The PV module mounting system as defined in claim 12, wherein each of the supports has an aperture in the distal end, and wherein the locations of the apertures corresponds to the locations of mounting apertures in the PV module.
 22. The PV module mounting system as defined in claim 12, wherein the plurality of supports can be adjustably positioned at a plurality of locations on each of the mounting bases. 